Cover assemblies for cables and electrical connections and methods for making and using the same

ABSTRACT

An integral, unitary cover assembly for covering an electrical connection between first and second electrical cables each having a primary conductor and a neutral conductor includes an inner elastomeric sleeve, an outer elastomeric sleeve and a duct member. The inner sleeve defines a cable passage to receive the electrical connection and the primary conductors of the first and second cables. The outer sleeve surrounds the inner sleeve. The duct member is interposed between the inner and outer sleeves. The duct member defines a neutral conductor passage configured to receive at least one of the neutral conductors therethrough.

FIELD OF THE INVENTION

The present invention relates to electrical cables and connections and,more particularly, to protective covers for electrical cables andelectrical connections.

BACKGROUND OF THE INVENTION

Cold shrinkable covers are commonly employed to protect or shieldelectrical power cables and connections (e.g., low voltage cables up toabout 1000 V and medium voltage cables up to about 46 kV). Oneapplication for such covers is for splice connections between concentricneutral cables. A concentric neutral cable typically includes at leastone primary conductor surrounded by a polymeric insulation layer, aconductive layer, one or more neutral conductors surrounding theconductive layer, and a polymeric jacket surrounding the neutralconductors. Examples of cold shrinkable covers for use with concentricneutral cables include the “All-in-One” CSJA Cold Shrinkable joint,available from Tyco Electronics Corporation of Fuquay-Varina, N.C.,which includes an integral neutral conductor mesh. It is also known tocover splices between concentric neutral cables using a cold shrinkelastomeric cover tube (such as the CSJ™ product, available from TycoElectronics Corporation) in combination with a separate re-jacketingcover (such as the GELWRAP™ product, available from Tyco ElectronicsCorporation). In this case, the cold shrink tube is installed over theprimary conductors and the insulation layers, the neutral conductors arelaid over the cold shrink tube, and the re-jacketing cover issubsequently wrapped around the neutral conductors and the insulationlayer. Each of these known methods may suffer from problems orlimitations in performance and/or installation.

SUMMARY OF THE INVENTION

According to embodiments of the present invention, an integral, unitarycover assembly for covering an electrical connection between first andsecond electrical cables each having a primary conductor and a neutralconductor includes an inner elastomeric sleeve, an outer elastomericsleeve and a duct member. The inner sleeve defines a cable passage toreceive the electrical connection and the primary conductors of thefirst and second cables. The outer sleeve surrounds the inner sleeve.The duct member is interposed between the inner and outer sleeves. Theduct member defines a neutral conductor passage configured to receive atleast one of the neutral conductors therethrough.

According to some embodiments, the duct member is rigid or semi-rigid.

In some embodiments, the duct member is tubular.

According to some embodiments, the cover assembly includes a second ductmember interposed between the inner and outer sleeves. The second ductmember defines a second neutral conductor passage configured to receiveat least one of the neutral conductors therethrough.

In some embodiments, the cover assembly extends along a lengthwise axisfrom a cover first end to a cover second end, and the inner sleeve, theouter sleeve and the duct member each extend lengthwise and have arespective first end proximate the cover first end and a respectivesecond end proximate the cover second end. The outer sleeve may includean extension section that extends lengthwise beyond the first end of theduct member. In some embodiments, the extension section of the outersleeve extends lengthwise beyond the first end of the inner sleeve.

According to some embodiments, the outer sleeve is formed of ethylenepropylene diene monomer (EPDM) rubber. According to some embodiments,the inner sleeve is formed of silicone rubber.

In some embodiments, the cover assembly includes a Faraday cage sleevemounted within the inner sleeve and formed of an electrically conductiveelastomer.

The cover assembly may include a stress cone sleeve mounted within theinner sleeve proximate an end thereof. The stress cone sleeve is formedof an electrically conductive elastomer.

According to some embodiments, the cover assembly includes asemiconductor layer mounted on an outer side of the inner sleeve andformed of an electrically conductive elastomer.

The cover assembly may further include a removable holdout devicemounted within the inner sleeve. The holdout device is operative totemporarily maintain the inner sleeve and the outer sleeve in anexpanded state.

According to some embodiments, the cover assembly is a cold shrinkablecover assembly.

According to further embodiments of the present invention, a connectionassembly includes: first and second electrical cables each including aprimary conductor and at least one neutral conductor; a connectorcoupling the primary conductors of the first and second cables to forman electrical connection; and an integral, unitary cover assembly. Thecover assembly includes an inner elastomeric sleeve, an outerelastomeric sleeve and a duct member. The inner sleeve defines a cablepassage. The outer sleeve surrounds the inner sleeve. The duct member isinterposed between the inner and outer sleeves. The duct member definesa neutral conductor passage. The electrical connection and the primaryconductors of the first and second cables extend through the cablepassage and the at least one neutral conductor of the first cableextends through the neutral conductor passage of the duct member and iscoupled to the at least one neutral conductor of the second cable.

According to some embodiments, the first and second cables are eachjacketed concentric neutral cables. Each of the first and second cablesincludes an insulation layer surrounding the primary conductor thereofand electrically insulating the primary conductor from the at least oneneutral conductor thereof. The primary conductor, the insulation layerand the at least one neutral conductor are relatively concentricallyconfigured.

In some embodiments, the at least one neutral conductor of the firstcable includes a plurality of neutral conductors extending through theneutral conductor passage and being coupled to at least one neutralconductor of the second cable.

According to some embodiments, the cover assembly is a cold shrinkablecover assembly.

According to method embodiments of the present invention, a method forforming a connection assembly includes: forming an electrical connectionbetween first and second electrical cables, the first and second cableseach including a primary conductor and at least one neutral conductor;providing an integral, unitary cover assembly including an innerelastomeric sleeve defining a cable passage, an outer elastomeric sleevesurrounding the inner sleeve, and a duct member interposed between theinner and outer sleeves, the duct member defining a neutral conductorpassage; inserting the at least one neutral conductor of the first cablethrough the neutral conductor passage of the duct; mounting the coverassembly on the cables such that the electrical connection and theprimary conductors of the first and second cables extend through thecable passage; and coupling the at least one neutral conductor of thefirst cable with the at least one neutral conductor of the second cable.

According to some embodiments, the cover assembly is a cold shrinkablecover assembly.

According to further method embodiments of the present invention, amethod for forming an integral, unitary cover assembly for covering anelectrical connection between first and second electrical cables eachhaving a primary conductor and a neutral conductor includes: forming aninner elastomeric sleeve defining a cable passage to receive theelectrical connection and the primary conductors of the first and secondcables; forming an outer elastomeric sleeve surrounding the innersleeve; and interposing a duct member between the inner and outersleeves, the duct member defining a neutral conductor passage configuredto receive at least one of the neutral conductors therethrough.

In some embodiments, the method includes integrally molding the ductmember between the inner elastomeric sleeve and the outer elastomericsleeve.

The method may include mounting the inner and outer sleeves with theduct member interposed therebetween on a holdout device, wherein theholdout device is operative to temporarily maintain the inner sleeve andthe outer sleeve in an expanded state.

According to some embodiments, the cover assembly is a cold shrinkablecover assembly.

Further features, advantages and details of the present invention willbe appreciated by those of ordinary skill in the art from a reading ofthe figures and the detailed description of the preferred embodimentsthat follow, such description being merely illustrative of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pre-expanded unit including a coverassembly and a holdout device according to some embodiments of thepresent invention.

FIG. 2 is a cross-sectional view of the pre-expanded unit of FIG. 1taken along the line 2-2 of FIG. 1.

FIG. 3 is a cross-sectional view of the pre-expanded unit of FIG. 1taken along the line 3-3 of FIG. 2.

FIG. 4 is a perspective view of a duct member forming a part of thecover assembly of FIG. 1.

FIG. 5 is a perspective view of an exemplary concentric neutral cable.

FIGS. 6-9 are side views illustrating procedures for installing thecover assembly of FIG. 1 on a pair of concentric neutral cables coupledby a connector.

FIG. 10 is a cross-sectional view of the covered splice connection ofFIG. 9.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown. In the drawings, the relativesizes of regions or features may be exaggerated for clarity. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiments set forth herein; rather,these embodiments are provided so that this disclosure will be thoroughand complete, and will fully convey the scope of the invention to thoseskilled in the art.

It will be understood that when an element is referred to as being“coupled” or “connected” to another element, it can be directly coupledor connected to the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlycoupled” or “directly connected” to another element, there are nointervening elements present. Like numbers refer to like elementsthroughout. As used herein the term “and/or” includes any and allcombinations of one or more of the associated listed items.

In addition, spatially relative terms, such as “under”, “below”,“lower”, “over”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. It will beunderstood that the spatially relative terms are intended to encompassdifferent orientations of the device in use or operation in addition tothe orientation depicted in the figures. For example, if the device inthe figures is turned over, elements described as “under” or “beneath”other elements or features would then be oriented “over” the otherelements or features. Thus, the exemplary term “under” can encompassboth an orientation of over and under. The device may be otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

With reference to FIGS. 1-4, a cover assembly 100 according to someembodiments of the present invention is shown therein. The coverassembly 100 includes a Faraday cage layer 122, stress cone layers 124,an inner sleeve (or insulation body) 130, a semiconductor layer 139, anouter sleeve (or re-jacket) 140, a first duct member 150, and a secondduct member 160, as discussed in more detail below. The cover assembly100 may be used to cover and electrically insulate electrical substratessuch as cables and connectors. The cover assembly 100 may be provided asa pre-expanded unit 101 including a holdout device 102, as shown inFIGS. 1-3, wherein the cover assembly 100 is in an expanded state orposition. The cover assembly 100 may be deployed and mounted on theintended substrate in a retracted state or position as shown in FIGS. 9and 10 and discussed in more detail below. According to someembodiments, the cover assembly 100 is a cold shrink cover, meaning thatit can be shrunk or retracted about the substrate without requiring theuse of applied heat.

The cover assembly 100 may be used to cover and seal a connection orsplice between two or more cables 40, 50 including a connector 60 toform a connection assembly 10 as shown in FIGS. 9 and 10. According tosome embodiments, the cables 40, 50 are concentric neutral cables.

Referring to FIGS. 1-3, the cover assembly 100 has a lengthwise axisA-A. The Faraday cage layer 122, the stress cone layers 124, the innersleeve 130, the semiconductor layer 139, the outer sleeve 140, the firstduct member 150, and the second duct member 160 are provided as anintegral, unitary structure extending lengthwise along the axis A-A.According to some embodiments, the cover assembly 100 is providedpre-installed and pre-expanded on the holdout 102.

The inner sleeve 130 has opposed inner and outer surfaces 130A and 130B,and opposed ends 132A, 132B. The inner sleeve 130 is tubular and definesan axially extending conductor through passage 136 that communicateswith opposed end openings 134A, 134B.

The Faraday cage layer 122 is illustrated as a generally tubular sleevebonded to the inner surface 120 of the inner sleeve 130. The Faradaycage layer 122 may be formed of a suitable elastically conductiveelastomer. In use, the Faraday cage layer 122 may form a Faraday cage toprovide an equal potential volume about the connector 60 so that anelectric field is cancelled in the surrounding air voids.

The stress cone layers 124 are illustrated as generally tubular sleevesbonded to the inner surface 130A of the inner sleeve 130 at either end132A, 132B thereof. The stress cone layers 124 may be formed of asuitable electrically conductive elastomer. In use, the stress conelayers 124 may serve to redistribute the voltage along the surface ofthe cable insulation 44, 54 to reduce or prevent the degradation of theinsulation 44, 54 that might otherwise occur.

According to some embodiments, the layers 122, 124 are formed of amaterial having a Modulus at 100 percent elongation (M100) in the rangeof from about 0.68 to 0.88 MPa.

The semiconductor layer 139 fully circumferentially surrounds the innersleeve 130. According to some embodiments, the semiconductor layer 139is coextensive with the inner sleeve 130.

The outer sleeve 140 has opposed inner and outer surfaces 140A and 140B,and opposed ends 142A, 142B. The inner sleeve 140 is tubular and definesan axially extending conductor through passage that communicates withopposed end openings 144A, 144B. When mounted on the holdout 102 asshown in FIGS. 1-3, outer sections 149 of the outer sleeve 140 arefolded back on an intermediate section 148 of the outer sleeve 140 atannular folds 149A.

The duct members 150, 160 may be constructed in the same manner andtherefore only the duct member 150 will be described in detail, it beingappreciated that this description likewise applies to the duct member160. The duct member 150 has opposed ends 152A, 152B disposed adjacentthe opposed ends 132A, 132B of the inner sleeve 130. The duct member 150is tubular and defines a neutral conductor passage 156 (FIG. 2)extending axially therethrough and communicating with opposed endopenings 154A, 154B. The cross-sectional shapes of the duct member 150and the passage 156 are generally rectangular; however, other shapes(e.g., circular, trapezoidal) may be employed. The inner wall of theduct member 150 may be somewhat curvilinear or rounded in cross-sectionas shown to conform to the circular outer diameter of the inner sleeve130.

The duct member 150 is disposed in a void or passage 170 (FIG. 3)defined between the inner sleeve 130 and the outer sleeve 140.Similarly, the duct member 160 is disposed in a void or passage 172(FIG. 3) defined between the inner sleeve 130 and the outer sleeve 140.Thus, the duct members 150, 160 are sandwiched between the sleeves 130,140 and thereby electrically insulated from both the conductor passage136 and the environment.

The semiconductor layer 139 can be formed of any suitable electricallysemiconductive material. According to some embodiments, thesemiconductor layer 139 is formed of an elastically expandable material.According to some embodiments, the semiconductor layer 139 is formed ofan elastomeric material. According to some embodiments, thesemiconductor layer 139 is formed of carbon black and silicone. Othersuitable materials may include carbon black and EPDM.

The inner sleeve 130 can be formed of any suitable material. Accordingto some embodiments, the inner sleeve 130 is formed of a dielectric orelectrically insulative material. According to some embodiments, theinner sleeve 130 is formed of an elastically expandable material.According to some embodiments, the inner sleeve 130 is formed of anelastomeric material. According to some embodiments, the inner sleeve130 is formed of liquid silicone rubber (LSR). Other suitable materialsmay include EPDM or ethylene propylene rubber (EPR). According to someembodiments, the inner sleeve 130 has a Modulus at 100 percentelongation (M100) in the range of from about 0.4 to 0.52 MPa.

According to some embodiments, the thickness T1 (FIG. 3) of the innersleeve 130 is in the range from about 0.07 to 1 inch. According to someembodiments, the length L1 (FIG. 2) of the inner sleeve 130 is in therange from about 8 to 30 inches.

The outer sleeve 140 can be formed of any suitable material. Accordingto some embodiments, the outer sleeve 140 is formed of an electricallyinsulative material. According to some embodiments, the outer sleeve 140is formed of an elastically expandable material. According to someembodiments, the outer sleeve 140 is formed of an elastomeric material.According to some embodiments, the outer sleeve 140 is formed ofethylene propylene diene monomer (EPDM) rubber. Other suitable materialsmay include neoprene or other rubber. According to some embodiments, theouter sleeve 140 has a Modulus at 100 percent elongation (M100) in therange of from about 0.6 to 1.1 MPa.

According to some embodiments, the thickness T2 (FIG. 3) of the outersleeve 140 is in the range of from about 0.11 to 0.25 inch. According tosome embodiments, the length L2 (FIG. 9) of the outer sleeve 140 is inthe range of from about 15 to 35 inches. According to some embodiments,the length L3 (FIG. 2) of each outer section 149 of the outer sleeve 140is in the range of from about 10 to 25 percent greater than the lengthL2.

Each duct member 150, 160 can be formed of any suitable material.According to some embodiments, the duct members 150, 160 are formed ofan electrically insulative material. According to some embodiments, theduct members 150, 160 are formed of a non-elastically expandablematerial. According to some embodiments, the members 150, 160 are formedof a polymeric material. According to some embodiments, the duct members150, 160 are formed of plastic. Other suitable materials may include ametal such as copper or aluminum. According to some embodiments, theduct members 150, 160 are rigid or semi-rigid.

According to some embodiments, the thickness T3 (FIG. 3) of each ductmember 150, 160 is in the range of from about 0.02 to 0.1 inch.According to some embodiments, each duct member 150, 160 has a width W(FIG. 4) in the range of from about 0.25 to 1 inch. According to someembodiments, each duct member 150, 160 has a height of H (FIG. 4) in therange of from about 0.25 to 0.5 inch. According to some embodiments,each duct member 150, 160 has a length L4 (FIG. 4) in the range of fromabout 8 to 10 inches greater than the length L1 of the inner sleeve 130.

The holdout 102 can be formed of any suitable material. According tosome embodiments, the holdout 102 is formed of a rigid cardboard orplastic. According to some embodiments, the holdout 102 includes a striphelically wound to form a rigid cylinder as illustrated, for example.The holdout device 102 may be factory installed. In some embodiments,the cover assembly 100 may instead be pre-expanded in the field using asuitable expansion tool.

The cover assembly 100 may be formed by any suitable method andapparatus. According to some embodiments, the inner sleeve 130 is moldedand the outer sleeve 140 is thereafter insert overmolded about the innersleeve 130 with the duct member 150, 160 interposed therebetween.

According to further embodiments, the inner sleeve 130 and the outersleeve 140 are separately formed (for example, by molding or extrusion)and thereafter the outer sleeve 140 is mounted on the inner sleeve 130.

According to some embodiments, the inner sleeve 130 is unitarily molded.According to some embodiments, the outer sleeve 140 is unitarily molded.According to some embodiments, the duct members 150, 160 are eachunitarily molded.

Alternatively, one or more of the inner sleeve 130, the outer sleeve 140and the duct members 150, 160 may be extruded. According to someembodiments, one or more of these components is unitarily extruded.

Referring now to FIGS. 5-10, the unit 101 may be used in the followingmanner to apply the cover 100 over a splice connection 15 (FIG. 6)between a pair of electrical power transmission cables 40, 50 to form aconnection assembly 10. According to some embodiments, the cables 40, 50are low-voltage or medium-voltage (e.g., between about 5 and 46 kV)power transmission cables. As shown in FIG. 5, the cable 40 includes aprimary electrical conductor 42, a polymeric insulation layer 44, asemiconductor layer 45, one or more neutral conductors 46, and a jacket48, with each component being concentrically surrounded by the next.According to some embodiments and as shown, the neutral conductors 46are individual wires, which may be helically wound about thesemiconductor layer 45. The primary conductor 42 may be formed of anysuitable electrically conductive materials such as copper (solid orstranded). The polymeric insulation layer 44 may be formed of anysuitable electrically insulative material such as crosslinkedpolyethylene (XLPE) or EPR. The semiconductor layer 45 may be formed ofany suitable semiconductor material such as carbon black with silicone.The neutral conductors 46 may be formed of any suitable material such ascopper. The jacket 48 may be formed of any suitable material such asEPDM. The cable 50 is similarly constructed with a primary electricalconductor 52, a polymeric insulation layer 54, a semiconductor layer 55,one or more neutral conductors 56, and a jacket 58 corresponding tocomponents 42, 44, 45, 46 and 48, respectively.

The connection assembly 10 may be formed and the cover assembly 100 maybe installed as follows. The cables 40, 50 are prepared as shown in FIG.5 such that a segment of each layer extends beyond the next overlyinglayer, except that the neutral conductors 46 of the cable 40 extend atleast a prescribed distance beyond the end of the primary conductor 42.This excess length of the conductors 46 can be folded back away from theterminal end of the primary conductor 42 as shown in FIG. 6.

The pre-expanded unit 101 is slid over the cable 50 as shown in FIG. 6.According to some embodiments, the inside diameter of the holdout 102 isgreater than the outer diameter of each cable 40, 50 such that the innerdiameter of the holdout 102 is sufficient to receive the prepared cable40, 50 and the connector 60 without undue effort. According to someembodiments, the inner diameter of the holdout 102 is at least as greatas the outer diameter of the largest portion of the cables or connectorsthat are to be received in the passage 136. The pre-expanded unit 101may be retained or parked on the cable 50 until the operator is ready toinstall the cover assembly 100 on the cables 40, 50.

The electrical connector 60 is secured to each primary conductor 42, 52to mechanically and electrically couple the primary conductors 42, 52 toone another as shown in FIG. 6. The connector 60 may be any suitabletype of connector such as a metal crimp connector.

The pre-expanded unit 101 is then slid into position over the connector60. The holdout 102 is then removed from the cover assembly 100, therebypermitting the elastomeric sleeves 130, 140 to relax and radiallyretract about the cables 40, 50 and the connector 60 as shown in FIG. 7.According to some embodiments, the inner sleeve 130 overlaps and engagesthe semiconductor layers 44, 54 of the cables 40, 50.

The excess length of the neutral conductors 46 is routed or threadedthrough the passages 156, 166 of the duct members 150, 160. The neutralconductors 46 are then electrically and mechanically coupled to theneutral conductors 56 by any suitable neutral connectors 70 as shown inFIG. 8. Each neutral connector 70 may be any suitable connector such asa metal crimp connector. As shown in FIG. 8, the neutral conductors 56of the two cables 40, 50 may be coupled to one another on only one sideof the connector 60. Alternatively, the neutral conductors 56 may becoupled to one another on both sides of the connector 60.

Strips of sealant 64 may be applied to the outer surfaces of the cablejackets 48, 58. The operator then rolls each up the extension sections149 of the outer sleeve 140 axially outwardly to cover the adjacentsections of the cables 40 and 50, respectively. According to someembodiments, at least a portion of each extension section 149 overlaps arespective portion of each cable jacket 48, 58 and engages theassociated sealant strip 64 to provide a moisture seal. The coverassembly 100 is thereby fully installed to form the connection assembly10 as shown in FIGS. 9 and 10.

Optionally, the neutral conductors 46 can be routed through the ductmembers 150, 160 after the holdout 102 has been removed and the coverassembly 100 has been initially secured about the splice connection 15.Also, while the neutral conductors 46 are shown routed through both ofthe duct members 150, 160, only one of the duct members 150, 160 may beused. According to further embodiments, the cover assembly 100 mayinclude more or less than two duct members and the duct members may bedisposed at different positions about the circumference of the coverassembly 100.

The relaxed inner diameter of the outer sleeve 140 is less than at leastthe outer diameter of the jacket layers 48, 58. Therefore, the outersleeve 140 exerts a radially inwardly compressive or clamping force orpressure (due to elastic tension) onto the cables 40, 50. The outersleeve 140 thereby effects a liquid tight seal at the interface betweenthe cable jackets 48, 58 and the outer sleeve 140. This seal can protectthe cable and the splice from the ingress of environmental moisture.According to some embodiments the relaxed inner diameter of the innersleeve 130 is at least 10% less than the smallest diameter cable uponwhich the cover assembly 100 is intended to be installed.

Cover assemblies and methods of the present invention and as describedherein can provide a number of advantages. The cover assembly 100provides an “all-in-one” integral unit that can be installed in similarfashion to known cold shrink splice cover insulating tubes and that alsoaccommodates the neutral conductors of concentric neutral cables. Thecover assembly 100 including the inner sleeve 130, the outer sleeve 140and the duct members 150, 160 can be preassembled at a factory.Therefore, it is not necessary to provide and install a separate andsupplemental re-jacketing cover to cover the neutral conductors (whichmust be electrically insulated from the primary conductors 42, 52 andthe primary connector 60).

The cover assembly 100 can also provide advantages over known“all-in-one” integral units of the type wherein an electricallyconductive mesh is incorporated into the cover assembly to engage andprovide continuity between the neutral conductors (typically, coppertapes) of the concentric neutral cables. In particular, in the case ofthese known cover assemblies, the electrically conductive mesh may notbe sufficiently conductive to provide the amount of continuity desiredor required. For example, the neutral conductors of the cables beingspliced may have a greater combined gauge than that of the connectingmesh. By permitting the use of the original neutral conductors of thecables 40, 50, the cover assembly 100 can ensure that the neutralconductors provided across the cover assembly 100 and the spliceconnection 15 are of the proper gauge. In this way, adequate continuitybetween the cables 40, 50 can be ensured.

The cover assemblies and methods of the present invention also permitthe operator to form the connection with only a single connection (forexample, crimp connection) between the neutral conductors of one cableand the neutral conductors of the other cable. Moreover, thisconfiguration permits the operator to form the connection with a crimpon only one side of the splice.

More generally, the cover assemblies and methods of the presentinvention can provide improvements in ease of installation. For example,in embodiments wherein the duct members are rigid or semi-rigid, theneutral conductors can be conveniently inserted through the passages ofthe duct members.

While in the embodiments shown in the drawings the neutral conductorsare wires, according to further embodiments the neutral conductors maytake other shapes or configurations such as one or more flat tapes.

While the duct members 150, 160 as illustrated extend the full length ofthe inner sleeve 130, according to other embodiments, the duct membersextend only partially (i.e., a distance less than the full length)across the inner sleeve 130.

Cover assemblies according to some embodiments of the present inventionmay include additional layers and/or certain layers may be omitted. Forexample, cover assemblies in accordance with some embodiments of thepresent invention may be formed without the semiconductor layer 139. Oneor more additional layers may be interposed between the inner sleeve 130and the outer sleeve 140.

Cover assemblies according to embodiments of the invention may be usedfor any suitable cables and connections. Such cable assemblies may beadapted for use, for example, with connections of medium voltage cablesup to about 46 kV.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention. Therefore,it is to be understood that the foregoing is illustrative of the presentinvention and is not to be construed as limited to the specificembodiments disclosed, and that modifications to the disclosedembodiments, as well as other embodiments, are intended to be includedwithin the scope of the invention.

1. An integral, unitary cover assembly for covering an electricalconnection between first and second electrical cables each having aprimary conductor and a neutral conductor, the cover assemblycomprising: an inner elastomeric sleeve defining a cable passage toreceive the electrical connection and the primary conductors of thefirst and second cables; an outer elastomeric sleeve surrounding theinner sleeve; and a duct member interposed between the inner and outersleeves, the duct member defining a neutral conductor passage configuredto receive at least one of the neutral conductors therethrough.
 2. Thecover assembly of claim 1 wherein the duct member is rigid orsemi-rigid.
 3. The cover assembly of claim 1 wherein the duct member istubular.
 4. The cover assembly of claim 1 including a second duct memberinterposed between the inner and outer sleeves, the second duct memberdefining a second neutral conductor passage configured to receive atleast one of the neutral conductors therethrough.
 5. The cover assemblyof claim 1 wherein the cover assembly extends along a lengthwise axisfrom a cover first end to a cover second end, and the inner sleeve, theouter sleeve and the duct member each extend lengthwise and have arespective first end proximate the cover first end and a respectivesecond end proximate the cover second end.
 6. The cover assembly ofclaim 5 wherein the outer sleeve includes an extension section thatextends lengthwise beyond the first end of the duct member.
 7. The coverassembly of claim 6 wherein the extension section of the outer sleeveextends lengthwise beyond the first end of the inner sleeve.
 8. Thecover assembly of claim 1 wherein the outer sleeve is formed of ethylenepropylene diene monomer (EPDM) rubber.
 9. The cover assembly of claim 1wherein the inner sleeve is formed of silicone rubber.
 10. The coverassembly of claim 1 including a Faraday cage sleeve mounted within theinner sleeve and formed of an electrically conductive elastomer.
 11. Thecover assembly of claim 1 including a stress cone sleeve mounted withinthe inner sleeve proximate an end thereof wherein the stress cone sleeveis formed of an electrically conductive elastomer.
 12. The coverassembly of claim 1 including a semiconductor layer mounted on an outerside of the inner sleeve and formed of an electrically conductiveelastomer.
 13. The cover assembly of claim 1 further including aremovable holdout device mounted within the inner sleeve, wherein theholdout device is operative to temporarily maintain the inner sleeve andthe outer sleeve in an expanded state.
 14. The cover assembly of claim 1wherein the cover assembly is a cold shrinkable cover assembly.
 15. Aconnection assembly comprising: first and second electrical cables eachincluding a primary conductor and at least one neutral conductor; aconnector coupling the primary conductors of the first and second cablesto form an electrical connection; an integral, unitary cover assemblyincluding: an inner elastomeric sleeve defining a cable passage; anouter elastomeric sleeve surrounding the inner sleeve; and a duct memberinterposed between the inner and outer sleeves, the duct member defininga neutral conductor passage; wherein the electrical connection and theprimary conductors of the first and second cables extend through thecable passage and the at least one neutral conductor of the first cableextends through the neutral conductor passage of the duct member and iscoupled to the at least one neutral conductor of the second cable. 16.The connection assembly of claim 15 wherein the first and second cablesare each jacketed concentric neutral cables, each of the first andsecond cables including an insulation layer surrounding the primaryconductor thereof and electrically insulating the primary conductor fromthe at least one neutral conductor thereof, the primary conductor, theinsulation layer and the at least one neutral conductor being relativelyconcentrically configured.
 17. The connection assembly of claim 16wherein the at least one neutral conductor of the first cable includes aplurality of neutral conductors extending through the neutral conductorpassage and being coupled to at least one neutral conductor of thesecond cable.
 18. The connection assembly of claim 15 wherein the coverassembly is a cold shrinkable cover assembly.
 19. A method for forming aconnection assembly, the method comprising: forming an electricalconnection between first and second electrical cables, the first andsecond cables each including a primary conductor and at least oneneutral conductor; providing an integral, unitary cover assemblyincluding: an inner elastomeric sleeve defining a cable passage; anouter elastomeric sleeve surrounding the inner sleeve; and a duct memberinterposed between the inner and outer sleeves, the duct member defininga neutral conductor passage; inserting the at least one neutralconductor of the first cable through the neutral conductor passage ofthe duct; mounting the cover assembly on the cables such that theelectrical connection and the primary conductors of the first and secondcables extend through the cable passage; and coupling the at least oneneutral conductor of the first cable with the at least one neutralconductor of the second cable.
 20. The method of claim 19 wherein thecover assembly is a cold shrinkable cover assembly.
 21. A method forforming an integral, unitary cover assembly for covering an electricalconnection between first and second electrical cables each having aprimary conductor and a neutral conductor, the method comprising:forming an inner elastomeric sleeve defining a cable passage to receivethe electrical connection and the primary conductors of the first andsecond cables; forming an outer elastomeric sleeve surrounding the innersleeve; and interposing a duct member between the inner and outersleeves, the duct member defining a neutral conductor passage configuredto receive at least one of the neutral conductors therethrough.
 22. Themethod of claim 21 including integrally molding the duct member betweenthe inner elastomeric sleeve and the outer elastomeric sleeve.
 23. Themethod of claim 21 including mounting the inner and outer sleeves withthe duct member interposed therebetween on a holdout device, wherein theholdout device is operative to temporarily maintain the inner sleeve andthe outer sleeve in an expanded state.
 24. The method of claim 21wherein the cover assembly is a cold shrinkable cover assembly.